HF Pre-Weld inspection system for tube mills
Real-time strip and welding measurement for High-Frequency tube and pipe manufacturing. See what's happening inside the weld box
HF Pre-Weld inspection system for tube mills
Real-time strip and welding measurement for High-Frequency tube and pipe manufacturing. See what's happening inside the weld box
High-Frequency welding depends on precise control of strip edge geometry, process variations and welding temperature. But most mills still operate with limited visibility to the welding process inside the weld box.
Traditional tools don't show the full process. Operators rely on experience, some indirect measurements, assumptions, and post-weld destructive testing.
You're no longer guessing.
Along with a clear view of the welding process, the latest HFPW system introduces additional data filtering algorithms and simplified operator display interface. This improve the reliability and accuracy of the system.
Strip edge geometry
Measure the precise geometry of strip edges as they enter the weld zone — the foundation of a controlled, repeatable weld.
Welding temperature
Monitor edge heating and the weld temperature profile across the weld bead in real time — not after the fact.
Process stability & variation
Monitor the welding process, with measurements and alarms to see when it changes and be able to address issues before it becomes a defect.
How it Works
The system uses the Xiris XIR-1800 thermal camera, mounted in a rugged industrial housing, combined with advanced software and an intuitive HMI.
Built for Real Production Environments
Improve Operator Safety
Operators gain a clear, real-time remote view of the HF welding process, reducing the need to interact directly with hazardous mill environments and minimizing production interruptions.100% Inspection Capability
The system delivers precise geometric and thermal measurements with customizable alarm and warning limits, allowing immediate corrective actions and consistent weld quality.
System Integration
HFPW integrates seamlessly with mill PLC systems and supports data sharing through OPC-UA and ModBus/TCP interfaces, enabling advanced automation, traceability, and data-driven manufacturing.
Xiris HF Pre-Weld Inspection system™ Datasheet
The Xiris HF Pre-Weld Inspection system, comprised of the XIR-1800 thermal camera in a protective housing and a HMI computer with tailored HF pre-weld software, enables operators to remotely monitor strip edges and the welding process of High-Frequency Tube Mills.
Learn more about HF Pre-Weld™ by downloading a copy of the datasheet by completing the form.
Built so solve real challenges.
Problems we designed around
Limited process visibility inside the weld box
Inconsistent weld quality across production runs
Dependence on operator experience and intuition
Lack of traceable, structured process data
The result
Greater process visibility
Measurable welding condition monitoring
Improved product quality / consistency
Reduced risk to operators
- Camera: SWIR, XIR-1800 HDR Thermal camera. (640 x 512 pixels)
- HFPW Sensor: 90 (Ø) x 300-600 mm (L), Weight ~ 5kg, Working Distance 400-650mm
- Temperature Measurement Range: 350 - 1500°C Standard Calibration, up to 2200°C with Extended Calibration
- Measurements: V- Angle, Weld Temperature, Bead Temperature, V-Length, Apex location, and more
Contact Support – Monday – Friday: 0830 – 1730 Eastern Standard Time
Phone: +1.905.331.6660
Fax: +1.905.331.6661
Email: support@xiris.com
Our partners also provides support and service to our clients at many locations around the world.
Service & Training: Xiris provides its customer base with various levels of service, including new system installation and training, system upgrades and preventative maintenance programs. Many of our partners are trained to offer additional support on our systems.
System Upgrades: Many of our older systems in the field have been upgraded to allow the use of new hardware and software features including improved system reliability, system security, production reporting and updated operating systems. Do you have an older Xiris vision system? Please call your Xiris account manager to receive more information regarding the immediate benefits of a system upgrade.
Preventative Maintenance Visits: Many of our clients request a Preventative Maintenance visit in conjunction with a new system delivery or as a separate service. Our technicians will optimize the performance of the system, upgrade software as applicable, look for potential part failures and conduct training as desired by the client during the visit.
Warranty: All Xiris systems are shipped with a 15-month warranty from the day of shipment from Xiris or a 12-month warranty which commences from the first day of use (whichever comes first). Please have your Xiris system serial number available when you call so we can determine your system warranty status as well as your support plan level.
Once your Warranty expires, your Xiris Account Manager will contact you to discuss your long term support needs. Xiris offers different levels of support plan.
Talk to our team
Frequently Asked Questions
What is the difference between ERW and HF Welding for Tube Mills?
ERW is Electro Resistance Welding and technically uses contact pads or rollers to induce an electric current in the part that creates the weld. HFW is High Frequency Welding whereby a non-contact work coil induces an electric current in the part to create the weld. The welding process is very similar, and the terms are often used interchangeably for Tube mills, but Xiris HF Pre-Weld (HFPW) system is intended specifically for HF welding.
Can Xiris HF Pre-Weld (HFPW) be used with non-ferrous materials like Aluminum, Copper or Brass that have lower temperature melting points?
Yes, this is possible and requires some customization to address the lower temperature profile of the welding.
Can the Xiris HF Pre-Weld system still work if the weld is flooded with coolant?
No, the Sensor cannot measure temperatures though water or coolant, but we can filter out effects from coolant droplets. With some coolant and environmental management water or coolant not normally and issue.
Is it possible to use the Xiris HF Pre-Weld with the WI system?
Yes, both WI and HFPW are often used together on the same mill. The Xiris HF Pre-Weld system is used before welding, while the WI system is placed after welding. Results from both systems can be captured in real-time via OPC-UA.
What Tube Sizes and Materials are best for HF Pre-Weld systems?
Typically, HF Pre-Weld is used in a larger diameter thicker walled Tube/Pipe, with Diameter > 50 mm and WT > 2mm. It however can work on any size tube or pipe where quality and process stability is critical.
Can the HF Pre-Weld system measure weld mismatch?
No, mismatch in the weld from Pipe or Tube forming, and many more geometrical weld bead measurements are done with Xiris WI2200/WI3000 system.
Xiris Automation Inc
Xiris Automation Inc
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